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grub, usb, raid, error 24

I am trying to setup openfiler (which is a redhat based distribution that creates a NAS) on a 2 gig usb with 4 * 1 TB drives in raid 5 running off of an sil sa3114 based sata controller.
If I remove the sata card so there is only the usb (sda1) I set grub to 'root (hd0,0)' and openfiler starts ok.
If I insert the sata card the usb becomes sde1 so I have to set grub to 'root (hd4,0)' and I get grub error 24 - block outside of partition - it does find grub.conf so (hd4,0) must be correct.
My head hurts!! - any help please